Method of making hammered ware



June 19, 1956 c, sc vu o 2,750,661

METHOD OF MAKING HAMMERED WARE Filed July 10, 1953 IN V EN TOR.

HIS AT ORNEY United States Patent "ice Mn'rrron or MAG RED WARE Angelo C. Scavullo, Jamaica, N. Y., assignor to Victor Scavullo, Frank Scavullo, Charles Scavullo, Marie Scavullo Saegert and Margaret Scavullo Scott Application July 10, 1953, Serial No. 367,192

3 Claims. (Cl. 29-553) My invention relates generally to ornamental metalware, and particularly concerns a method of imparting to semi-finished articles of this general type, particularly those formed of work-hardenable metal, a surface design or finish which closely simulates and approximates the pleasing appearance which attends upon the well-known hand hammering technique.

One object of my invention is to provide a method of producing a hand-hammered finish eifect on metal articles which is both rapid and inexpensive, and in the practice of which not only is the intended design imparted to all desired parts of the metal surface at the same moment, but as well the design thus produced is comprised of indentations of varying depth, some shallow, while some are deeper than others, all with varying configurations and surface dimensions.

Another object is to produce a simulated hand-hammered effect of the general type described on metal-ware of thetype disclosed which is particularly effective with work-hardenable metals, the requisite design being nicely imparted with a single blow of the impression die which is employed in the practice of my new method, and the practice of whichresults in a finish in which the various surface indentations are clear and sharp in impression, with margins which are crisply and clearly defined, without suggestion of blurring or lack of definition, all with pleasing lack of uniformity which is requisite to effective simulation of hand-hammering, all coupled with random depth and configuration of indentations which characterizes hand-crafted articles of this general type, and all with minimum investment in labor, plant and equipment, and employing equipment of maximum simplicity.

A still further object is to provide table-ware and other ornamental metal-ware of stainless steel, either the straight chromium or the chromium-nickel grades, on which accurate and pleasing simulation of hand-hammered finishing is achieved so rapidly and economically as to enable effective competition in the market with generally similar metal-ware having surface detail of lesser complexity.

Another object of my invention is to provide metalware, particularly articles formed of work-hardenable stainless steels, in which a close simulation of handhammering is nicely achieved with minimum investment in both plant and labor, all at minimum production cost and with ready and accurate reproduction, with surface indentations possessing sharply defined margins, together with varying dimensions both in depth and cross-section and with varying configuration, the While they depart considerably from any regularity or monotony of fishscale indentation, departing sharply from their characteristic uniform depth, surface configuration, rolled edges, and the like.

All these as well as many other highly practical objects and advantages attend upon the practice of my invention, which in part will be obvious and in part more fully pointed out hereinafter during the course of the 2,750,661 Patented June 19, 1956 following description, particularly when the latter is considered in the light of the accompanying drawing.

Accordingly, my invention may be considered as re-- siding in the several procedural and manipulative stepsand, in its relation therewith, the die which I employ and which, with a single stroke, imparts the desired pattern to: the metal stock; in the new products of manufacture produced through the practice of my method; and in the: correlation and combination of each of the manipulative steps with one or more of the others, the scope of the application of all of which is more fully detailed in the claims at the end of this specification.

As conducive to a more ready understanding of my invention it may be noted at this point that it has long been the practice, in handling and preparing rare metals: for ornamental use, or at least in such usage where ornamentation assumes appreciable importance, to achieve: this by hand-hammering the metal stock with a small: peening hammer or the like. This imparts a surface: finish which is highly pleasing to the eye. And such effect may reasonably be attributable to the many huh-- dreds of small faceted reflecting surfaces thus, achieved,. each oriented in a difierent direction, and the indentations differing at random amongst themselves both in size-,. configuration and depth. Some are shallow, while some: are comparatively deep; some are regular, some irregu-- lar in configuration. Some areround, while some are elliptical. As concerns nearly allthese indentations the departure from the comparatively smooth, pressed or machined surface of the base metal into the indentations; produced by the peening hammer is sharply defined, and comprises a distinct break in continuity, as distinguished from a continuous, compounded curve. The significance of this from the standpoint of ornamentation will be pointed out later herein. This sharp break, although unnoticed by direct observation, comprises one of the distinguishing characteristics of a hand-hammered surface.

When labor was comparatively cheap, and when rare metals were undergoing such ornamentation, hand-hammering could effectively be resorted to. For the increase in value thus imparted to the article, with-attendant high retail prices thereby obtainable, more than compensated for the increase in production hours. Moreover, such metals in the most part were comparatively soft and ductile, and usually could be worked to completion with out requiring resort to intermediate anneal.

Present-day high costs of production, however, makes it highly desirable to minimize the hand-crafting required, provided only this can be accomplished without detract-- ing from the beauty of the fabricated article. Not only do elevated living costs leave the purchaser with reduced.

pocketbook so that merchandise must be priced to meet: available funds, but, as Well, the cost at manufacturing level has soared to such extent that the manufacturer must minimize both the quantity and skill of labor required,. and hence maintain hourly wage bill at minimum figure. Additionally, he must decrease plant investment required both in space and equipment, and must increase the hourly output. Moreover, and again as a concession to increased cost of living and, as well, to the awakened perception in the general public to the niceties of life, the art has trended continually away from the rare metal products and towards those worked in such base metals, together with their alloys, as will effectively receive and hold a suitable finish treatment and at the same time will be relatively inactive and inert under normal conditions of use.

Particularly is this true as applies to the so-called stainless steels. For here the metal stock lends itself most eflectively to pleasing finish detail. The metal itself is pleasing to the eye, particularly when pickled and polished in a variety of' pleasing final surfaces. These.

metals, however, being largely non-precious, do not justify the use in their production of a considerable quantity of hand-crafting, with its attendant high cost. Moreover, such hand-crafting defeats the purpose of appealing to the low-cost market.

Accordingly, considerable attention has been given in recent years to simulating as closely as possible, through mechanical techniques, the surface indentations produced by hand-hammering. And various suggestions have been forthcoming to this end. Illustratively, in the field of soft metals the use of pressure rolls has been proposed, between and beneath which continuous metal strip is passed. And in point of fact, this is perhaps the only method which has received any considerable attention in the art. When these rollers are employed on intaglio or relief impression is first imparted thereto. These rolls pass continuously over a sheet of metal which is fed therebetween, following which the articles themselves are cut from the metal strip, and are thereupon shaped and finished in desired manner.

However, certain practical difiiculties inherent in the use of rolls prevent a really close and satisfactory approximation to hand-hammered effect through such procedure. For while with hand-hammering, as have been previously pointed out, the indentations are of indiscriminantly and widely varying configuration, depth and surface dimensions, due to variations in the strength and direction of the individual blow of the peening hammer, it is essential where rolls are used that the indentations be substantially uniform in depth. Moreover, they must be shallow. For if these conditions do not exist, the rolls tend to foul and the strip of work metal may become snarled in its passage between the rolls. As a result, at the best, a fishscale type of surface is produced, by way of compromise. In over-all effect, this is unpleasing to the eye, largely because of its uniformity. It lacks the irregularity of the hammer effect. Moreover, the edges of the indentations tend to roll over in the direction of rolling, due to the flow of the sheet metal and to the unidirectional drag of the rolls. The edges lack the crispness of the hammer effect. Uniformly, such rolls and techniques employing the same have not received acceptance in the art.

Not only does the use of stainless steels, satisfying low cost demand, occasion economic rejection of the thought of hand-hammering, but, as well, the physical charac-- teristics of the alloy metals usually put to such use effectively resist the successful use of such manufacturing methods. For the stainless steel usually employed is either straight chromium, or a nickel-chromium alloy where a whiter metal is desired, possibly with added titanium or molybdenum to give a still whiter metal. Usually these steels areof the 18-8 grade (18% chromium and 8% nickel). And while these are customarily referred to as austenitic metals, and presumably not hardenable, actually these alloys are not truly austenitic. And when subjected to hand-working them they tend to harden rapidly. This makes hand-crafting progressively difiicult until shortly it becomes well-nigh impossible to work the metal further without first subjecting it to intermediate anneal. Of course, such recourse greatly increases production costs. For not only is greater time consumed, but plant facilities for this special purpose are required, including a high-cost annealing furnace, increased requirements of space, increased labor bills, and sundry other items which in aggregate, materially increase production costs.

Thus, in brief summary, an important feature of my invention is to provide a method which can produce handhammered effect in close simulation of true hand-crafting; which can achieve this result without objectionable workhardening of the metal, thereby removing necessity for intermediate anneal; which can bring about the desired finish rapidly and with a single operation; which effectively avoids the fish-scale uniformity of impressions which attend upon the use of prior art methods, and

instead, closely follows the irregular and random depth, area and configuration of hand-produced indentations, all with use of simple and inexpensive equipment with only moderately skilled labor, production costs being kept at a minimum and with appreciable enhancement of the competitive position in the industry of the resulting products.

In the practice of my invention I form a die of suitable metal such as tool steel. Thereon I provide, in relief embossments which closely follow the configuration of hand-hammered indentations. These dies conveniently are formed in metal of requisite hardness, and displaying high resistance to wear. Illustratively, tool steel well answers this requirement. The required design is imparted in reverse relief or intaglio, in desired suitable manner. illustratively, such design may be imparted by suitable engraving process. Or if desired, the metal may be first annealed, then hand-peened while in soft condition, and thereafter hardened in a number of conventional manners. A die so formed, and employing suitable metals, can be eflectively employed throughout long periods of use, giving thousands of impressions of requisite sharp and accurate definition, and this without appreciable wear. The die thus produced is thereupon mounted in a suitable press, and is ready for use.

In the practice of my invention, 1 subject metal strip to a suitable cutting operation, striking therefrom the rough blanks, which approximate the shape and dimensions of the final articles. And this is so regardless of whether i am producing fiat-ware or hollow-ware, and whether the resulting product may be intended for tableuse or other ornamentation either in the home or in the office. Metal blanks for hollow-ware, thus produced, may be subjected to such additional manufacturing steps, such as deep-drawing, spinning, or the like, as may be required.

The formed blanks are then placed in the press, and then stamped with the die, bearing the design, and which has been produced in the manner hereinbefore referred to.

Only a single smack of the die is ordinarily required; and at the most, two such strokes are required even when complex surfaces are being followed. The press employed may be a drop press, or of other conventional design. The loading of the die, and the weight carried therewith, determines in large measure the force of the blow. Accordingly, this force can be nicely adjusted to the requirements of the particular objects being manufactured, and can be readily varied from job to job. The impression thus received in the metal work-piece is sharply defined, and conforms closely to the details of the die, with crisp, sharply defined margins, and with pleasing irregularities of indentations. This closely simulates the hand-hammering effect. Of course, such dies follow closely the designs and configurations of the finished article so that minimum after-treatment is required.

A typical form of installation which admirably enables the practice of my invention is illustratively shown in schematic form in the drawings attached hereto wherein, in single view, is shown a schematic embodiment of my invention.

Therein I provide a die 10 which is formed of tool steel or the like. Engraved or otherwise provided on the die is the design ill, which closely follows the exact contour of the indentations produced by hand-hammering. Ordinarily I form this die of tool steel. While I have suggested that the embossments on the die are formed by engraving, it is equally possible, as I have hereinbefore suggested, to form these embossments in other suitable manner. Ill'ustratively, handhammering can be resorted to, the tool steel being first annealed to soften the same. Then following such hand-hammering the die, if not already work-hardened to sufiicient extent, can be subjected to further heat-treatment, to harden the same.

Die 10 is mounted in a press or the like 12 of conventional form, and provides a single swipe against the work piece 13 of the like which is displayed opposite thereto, on table 14 or the like, both the table 14 and the press being mounted on the plant floor 15. The operator can either present the metal work pieces 13 beneath the die one by one while the die is in its raised position, or he can feed the work pieces laterally across the table 14, in serial manner. In either event, I prefer to provide foot or knee control or similar semi-automatic control, so that the operator can depress the die 11 as and when he wants to, and this with minimum effort. Of course, automatic feeding of the die can be resorted to, but the hazard attendant upon this operation is relatively great, unless automatic feeding of the work piece 13 is also resorted to. This latter, however, is within the contemplation of my invention.

By the practice of my invention, it is entirely possible to simulate closely the pleasing surface ornamentation which ordinarily can be achieved only by hand-hammering. Stereotyped regularity is efiectively departed from, and the fish-scale appearance which attends upon prior efforts in this direction is eifectively avoided. Surface configurations of varying and random dimensions and depth are achieved, just as in the case of hand-hammering.

Minimum labor requirements are involved, and such labor as is required need be of but moderate skill. Investment in machinery and other equipment is kept at a bare minimum, while space requirements, and hence rental costs, are maintained at a bottom figure. Rate of production is appreciably increased making entirely competitive the position of stainless steel articles of this gen eral type. Moreover, it is economically possible to impart pleasing surface ornamentation to stainless steel metalware without appreciable increase in the cost of producing the same. Work-hardening is eifectively avoided, and the necessity for intermediate anneal during the working operation is effectively suppressed.

Final treatment is largely eliminated, such treatment as is required being simple in nature. Illustratively pickling, for cleaning and polishing purposes, followed by a burnishing or a brush-scratching operation, is all that is required.

My new method is applicable as well to hollow-ware as it is to flat-ware. Moreover, it is by no means limited to table-ware, and can be eifectively imparted to other ornamental articles, either for the office or for the home. The new method makes it possible to impart readily the desired ornamental design to inexpensive steels of low chromium and nickel content, which ordinarily would work-harden to radical extent if subjected to a series of separate blows. The margins of the indentations which mark the departure from the plane of the metal into the surface of the indentations, are sharp and well defined, all blurring and tendency towards lack of definition being thereby effectively avoided. Faithful and rapid production of high grade articles with minimum of rejects is effectively achieved.

All the foregoing as well as many other highly practical advantages attend upon the practice of my invention.

From the foregoing it will be apparent that many modifications of the present embodiment will readily suggest themselves to those skilled in the art. And that, similarly, many embodiments, all incorporating my basic conception, will likewise present themselves. Accordingly, I intend the foregoing description to be considered solely as illustrative, and not as a limitation.

I claim as my invention:

1. The method of closely simulating hand-hammered ornamentation in metals with crisp and clear delineation of detail, comprising first imparting the hand-hammered design in relief on a suitable die by annealing the die metal, hand peening the same, and hardening; and then imparting this design in intaglio on a selected metal article, rough-blanked to approximately the desired configuration by striking the die thereagainst with a single blow.

2. The method of ornamenting the surface of metalware with crisp and clear delineation of detail simulating hand-hammering, comprising imparting the handhamrnered design in relief on a suitable die by peening annealed die metal and then hardening the same; imparting this design intaglio on the metal-Ware by striking the same with the die; and polishing the Ware to give light relief to the simulated hammered surface.

3. The method of producing stainless steel metal-ware having a crisp and clear simulated hand-hammered surface, comprising imparting a hand-hammered design on a die by annealing the die metal, peening the same, and hardening; striking the work-hardenable chromiumbearing stainless steel metal-ware, while in semi-formed condition with said die to harden the surface and impart the required simulated hand-hammered surface thereto; and finishing the ornamental semi-formed ware.

References Cited in the file of this patent UNITED STATES PATENTS 319,306 Palmer June 2, 1885 413,374 Paull Oct. 22, 1889 1,499,986 Kirsch July 1, 1924 1,736,495 Graif Nov. 19, 1929 1,940,767 Perkins Dec. 26, 1933 1,958,972 Miller May 15, 1934 2,577,423 Ludwig Dec. 4, 1951 

